Multi-Sensor Nonius Angle Measurement for Compact Rotary Detection
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Solution Overview
Problem
Existing sensor systems for measuring rotational movements face limitations in installation space and are susceptible to measurement errors due to the need for large gears and coordination of periodicities, which affects the accuracy and robustness of torque and steering angle calculations.
Innovation Solution
A sensor arrangement using at least three angle sensors with different transmission ratios and a cascaded nonius calculation to determine rotational movements, allowing for improved selection of periodicities and reduced installation space, while enhancing robustness against angle and hysteresis errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simple nonius calculation is used with two angle signals, then the measurement system is simpler, but the robustness against angle errors and hysteresis errors is reduced
Solution Approach 1:
The patent divides the angle measurement into multiple independent measurement paths with different transmission ratios. Instead of using a single nonius calculation with two signals, the system segments the measurement into multiple cascaded nonius calculations, each processing signals with different periodicities. This segmentation allows independent optimization of each measurement path and reduces the propagation of errors from any single path.
Solution Approach 2:
The patent performs preliminary angle measurements using multiple angle sensors with different transmission ratios before the final evaluation. By pre-acquiring angle signals with different periodicities and performing intermediate nonius calculations, the system prepares multiple candidate angle values that can be cross-validated. This preliminary action enables error detection and correction before the final angle determination, enhancing robustness against hysteresis and angle errors.
2Reliability
If large gears are used to coordinate periodicities of angle measurements, then the nonius calculation functionality is ensured, but the installation space requirement increases
Solution Approach 1:
The patent replaces the mechanical gear coordination system with an electronic signal processing system. Instead of using large physical gears to synchronize the periodicities of multiple angle sensors, the system uses electronic evaluation of angle signals with different transmission ratios. The coordination of periodicities is achieved through software-based nonius calculations rather than mechanical synchronization, dramatically reducing the required installation space while maintaining measurement accuracy and functionality.
Solution Approach 2:
The patent changes the transmission ratio parameters of multiple angle sensors to achieve different periodicities without requiring mechanical gear coordination. By selecting angle sensors with specific transmission ratios (e.g., 1:1, 2:1, 3:1), the system achieves the necessary periodicity differences for nonius calculation through parameter selection rather than mechanical transformation. This allows flexible adjustment of measurement parameters without changing the physical layout or requiring large coordination gears.
3Reliability
If multiple angle sensors with different transmission ratios are used in a cascaded nonius calculation, then the robustness against measurement errors is improved, but the device complexity increases
Solution Approach 1:
The patent makes the evaluation and control unit multi-functional by designing it to perform multiple cascaded nonius calculations with different transmission ratios. The same evaluation unit processes angle signals from multiple sensors, performs intermediate nonius calculations, validates results, and produces the final angle measurement. This universal approach consolidates what could be multiple separate measurement systems into a single integrated unit, reducing overall device complexity while maintaining the benefits of multiple measurement paths for enhanced robustness.
4Loss of information
If coordination of periodicities is enforced for nonius calculation, then the steering angle measurement range is ensured, but the options for inductive torque measurement periodicities are limited
Solution Approach 1:
The patent introduces dynamic adaptability into the measurement system by allowing different transmission ratios for different measurement purposes. The system can dynamically select which angle sensor signals to use for torque measurement based on the required periodicity, while maintaining the full measurement range for steering angle through the cascaded nonius calculation. This dynamic approach enables the system to optimize torque measurement periodicity independently of steering angle requirements, enhancing versatility without sacrificing measurement range completeness.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides increased accuracy and reduced susceptibility to measurement errors, enabling the use of more cost-effective magnetic circuits and mechanical gear systems, and ensures precise determination of rotational angles across multiple revolutions.
Implementation Method 1
at least three angle sensors which each acquire the mechanical rotational movement
Data Source
AI summary
A sensor arrangement for acquiring a rotational movement of a body that can rotate about a rotational axis has at least three angle sensors and at least one evaluation and control unit. The at least three angle sensors each acquire the mechanical rotational movement of the rotatable body with a predefined transmission ratio and generate a corresponding electrical angle signal and output said angle signal to the at least one evaluation and control unit. The at least three angle sensors have different transmission ratios. The at least one evaluation and control unit are designed to determine a first angle of the rotatable body with a first uniqueness range by way of a first nonius calculation that is based on two electrical angle signals of the at least three electrical angle signals. The first uniqueness range of the determined first angle is greater than uniqueness ranges of the angle signals used for the calculation. The at least one evaluation and control unit is further designed to determine a second angle of the rotatable body with a second uniqueness range by way of a second nonius calculation that is based on the determined first angle and a further electrical angle signal of the at least three electrical angle signals. The second uniqueness range of the determined second angle is greater than the first uniqueness range of the determined first angle and a uniqueness range of the further electrical angle signal. Also disclosed is a method for acquiring a rotational movement of a body that can rotate about a rotational axis which can be carried out using such a sensor arrangement.